Battery sealant carrier having adhesive patches impregnated therein and a method for making it

ABSTRACT

A battery sealant carrier is impregnated with adhesive patches each of which is in the form of a closed loop. The surfaces of the adhesive patches rise above the surfaces of the carrier on at least one and preferably both sides of the carrier. The patches are produced by passing the carrier between a pair of applicators, the first of which has a surface that is sufficiently rigid and uncompressible so that it does not deform and the second of which has a surface that is sufficiently elastomeric so that it deforms during adhesive application. Preferably the two applicators apply adhesive to the carrier simultaneously. The adhesive patches applied by the second applicator are preferably applied at a higher viscosity than those applied by the first applicator. Preferably the sealant carrier is also the battery separator material, in which case there is an area of separator material inside each adhesive patch into which the adhesive has not been impregnated; alternatively, the sealant carrier may have a void area inside each adhesive patch, with the void area being provided to receive a piece of battery separator material.

United States Patent [191 Macaulay et al.

[ BATTERY SEALANT CARRIER HAVING ADHESIVE PATCHES IMPREGNATED THEREINAND A METHOD FOR MAKING Inventors: William R. Macaulay, Madison;

Ralph H. Feldhake, Verona, both of Wis.; Dale G. Higgins, EastBrunswick; Richard C. Santa Maria, Edison, both of NJ.

Assignee:

Primary Examiner--Donald L. Walton A Howey Ra mo qkl B3 993- FIRSTAPPUCATOR, ZOl

(RlGlD,UNC.OMFRE5SABLE i SURFACE) commuous STRiP oF CARRlER uMATER\AL,4-O K secorw APP\ \cAroR,2OZ

(ELASTOMERKC.

57 ABSTRACT A battery sealant carrier is impregnated with adhesivepatches each of which is in the form of a closed loop. The surfaces ofthe adhesive patches rise above the surfaces of the carrier on at leastone and preferably both sides of the carrier. The patches are producedby passing the carrier between a pair of applicators, the first of whichhas a surface that is sufficiently rigid and uncompressible so that itdoes not deform and the second of which has a surface that is:sufficiently elastomeric so that it deforms during adhesive application.Preferably the two applicators apply adhesive to the carriersimultaneously. The adhesive patches applied by the second applicatorare preferably applied at a higher viscosity than those applied by thefirst applicator. Preferably the sealant carrier is also the batteryseparator material, in which case there is an area of separator materialinside each adhesive patch into which the adhesive has notbeenimpregnated; alternatively, the sealant carrier may have a void areainside each adhesive patch, with the void area being pro vided toreceive a piece of battery separator material.

22 Claims, 10 Drawing Figures SURFACE) oFFsET APPucAToR,

PATENTEBJMI 8 I974 SHEET 2 F SECOND APPucAToR, '20 Z (ELASTOMERK.SURFACE) FIRST APPUCATOR, 201 RlGlD, UNCOMPRESSABLE SURFACE) CONT\NUOUSSTRH OF CARP MATERiAL, 4o

ADH ES\\/E PATCHES ELECTR OLYTE ANDBOZ c NTmuous sTmP ox cmmexzMATEEAAL.

FlRsT AWESWE commuous sTRm OF PATCH) 301 CARRlER MATER\ AL,LO

SECOND ADHESWE PATCH PATENTEDJAM s 1974 SHEEI an? 5 PATENIEUJAI 8 m4SHEET l 0F 5 ll 02 W(MKU7:

tNCREAS\N6 TEMPERATURE 1 BATTERY SEALANT CARRIER HAVING ADHESIVE PATCHESIMPREGNATED THEREIN AND A METHOD FOR MAKING IT BACKGROUND OF THEINVENTION In US. Pat. No. 3,70l,690, it has been proposed to impregnatea series of patches into a sealant carrier composed of battery separatormaterial. Each patch of adhesive is in the form of a closed loop. Afterthe adhe-. sive patches have been impregnated the sealant carrier isassembled into a battery in such a manner that each adhesive patch issealed to a liquid impervious layer around the batterys electrodes. I

A number of factors must be considered in designing machinery and aprocess to implement the method proposed in Patent 3,701,690. Thequality of the seal obtained in the resultant battery is improved byhaving a deposit of adhesive on the liquid impervious layer which ismated with the sealant carrier before the two are sealed together, butthe very fact that the liquid impervious layer is impervious limits theamount of adhesive which can be applied to that layer. In order toobtain quality seals. therefore, it may be necessary to applysubstantial amounts of adhesive to the sealant carrier.

The adhesive must also be impregnated thoroughly into and throughout thethickness of the sealant carrier in order to prevent liquid from theelectrolyte from escaping from the battery through the sealant carrier.This objective is made difficultto achieve when the sealant carrier ismade from material which is also the battery separator since separatorsare intentionally made from materials which will hold and transmit theelectrolyte like a wick. And while adhesives may be impregnated intosealant carriers by methods analogous in some respects to the techniquesused in the printing arts, the analogy is incomplete in the crucialrespect that complete impregnation of an ink throughout the i thicknessof the substrate is seldom required in printing and, even where it is,the ink does not have the high viscosity possessed by adhesives.

Further complicating the matter is the fact that the sealant carriermust be under tension if it is to be processed as a continuous stripthrough rotary impregnating machinery. The tension produces stretchingin the sealant carrier which, due to the irregularities in the carriermaterial, is not consistent in amount, at least on a highly localizedbasis. The sealant carrier is also usually somewhat inelastic. As aresult of the stretching andthe properties of the sealant carrier,serious registration problems may be encountered if adhesive patches aredeposited on the two sides of the carrier in successive applications. Ifsimultaneous applications on both sides of the carrier are attempted theforces required to get the necessary thorough impregnation throughoutthe entire thickness of the carrier may, together with the properties ofthe carrier material, make it difficult or impossible to get therequired thorough impregnation.

SUMMARY OF THE INVENTION This invention provides patches of adhesivewhich are impregnated substantially throughout the entire thickness of abattery sealant carrier and in which the adhesive in the patch risesabove the surface of the sealant carrier on atleast one and preferablyboth sides of the carrier. Each patch is in theform of a closed loop.The sealant carrier preferably comprises battery separator material sothat there is an area of separator sealant carrier may have a void areainside each adhesive patch, the void area being provided to receive apiece of battery separator material during assembly of the battery.

The adhesive used to apply the second patch is preferably at a higherviscosity when applied onto the sealant carrier than is the adhesiveused to apply the first patch. The two patches are preferably appliedsimultaneously.

Preferably the first adhesive patch is applied by a first applicator thesurface of which has a recessed area in the configuration of the desiredadhesive patch and in which the recessed area contains adhesive to betiansferred to the adhesive carrier. The second patch is applied by asecond applicator on the surface of which is a quantity of adhesive,which quantity of adhesive is of the configuration of the desired secondpatch and which quantity of adhesive rises above the surface of thesecond applicator. The surface of the first applicator is sufficientlyrigid and uncompressible so that it does not deform substantially duringapplication of the first patch, while the second patch is applied by asec ond applicator the surface of which is sufficiently elastomeric sothat it deforms during application of the second patch. Y

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic viewillustrating a pair of applicators applying adhesive patches to theopposite sides of a continuous strip of porous sealant carrier material.

FIG. 2 is an exploded view of the sealant carrier and adhesiveapplicators shown in FIG. 1.

FIG. 3 illustrates the continuous strip of sealant carrier being passedbetween the adhesive applicators so that adhesive patches are appliedonto the opposite sides of the carrier simultaneously...

FIG. 4 shows a portion of the continuous sealant carrier after thepatches of adhesive have been impregnated into it.

FIG. 5 is a cross section of the portion of sealant carrier shown inFIG. 4 taken along the line AA of FIG. 4. r

FIG. 6 illustrates the sealant carrier being collated into a batterywhere the adhesive patches will provide seals.

FIG. 7 is an oblique view of a multicell battery con I being provided toreceive apiece of separator material during assembly of the battery;

DESCRIPTIONOF THE PREFERRED EMBODIMENT This invention is concerned withadhesive patches which areapplied onto andirnpregnated into asealantcarrier. The adhesive patches, eachof which is in the form of a closedloop, are used to obtain liquid impervi ousseals around the electrodesinbat'teries.

In the assembled batteries the area inside each adhesive patch will beoccupied by battery separator material and electrolyte. According to oneembodiment of this invention which minimizes the number of componentsand handling steps required to assemble the batteries, the sealantcarrier comprises battery separator material so that the separator andsealant carrier are always structurally and integrally connected duringbattery assembly. According to another embodiment which permits thesealant carrier material to be selected without regard for its abilityto function as a separator and electrolyte retainer, the sealant carrierhas a void area inside each adhesive patch, and a discrete piece ofseparator material is placed into each void area during assembly of thebattery. FIGS. 1 through 6 and 8 will illustrate constructions in whichthe sealant carrier comprises separator material, while FIG. 10 willillustrate the alternative construction in which there is a void areainside each adhesive patch.

FIGS. 1 through 3 illustrate a pair of applicators 201 and 202 which areused to apply a succession of adhesive patches 301 and 302 onto theopposite sides of continuous strip of sealant carrier 40. The carrier 40with its adhesive patches 301 and 302 is illustrated in FIG. 4 and 5. Asshown in FIG. 4, each patch is in the form of a closed loop inside ofwhich is an area of separator material 42 where the adhesive has notbeen applied; the area 42 will subsequently be impregnated withelectrolyte for the battery.

According to one of the principles of this invention the firstapplicator 201 applies the first patches 301 onto one side of thesealant carrier 40. Sufficient adhesive is applied by the firstapplicator 201 so that the surfaces of the resultant first patches 301rise above the surface of the carrier 40, as shown in FIGS. 3 and 5. Thesecond applicator 202 supplies second adhesive patches 302 onto theother side of the separator material 40, with the second patches 302being substantially opposite and coextensive with the first patches 301.The surfaces of the resultant second patches 302 also rise above thesurface of the sealant carrier. The resultant sealant carrier is thusprovided with the substantial amounts of adhesive needed to obtainquality seals in batteries. I

The second patch 302 is best obtained by having the second applicator202 apply its adhesive while that adhesive is at a higher viscosity thanthe adhesive which is applied by the first applicator. The differentviscosities have been found by experimentation to be desirable. Thedifferent viscosities may be obtained by using the same type ofadhesives on both sides of the carrier but heating them to differenttemperatures, or by using two different adhesives which have differentviscosities at the same temperatures. Volatile solvents or othermaterials may be included in the adhesives for the purpose ofcontrolling viscosity. The viscosity of the adhesive at the moment it isapplied onto the carrier may be controlled by temperature controlsinternal to the applicators and/or external temperature control devicessuch as hot air blowers, heating lamps, and others. The viscosity of theadhesive may be changed just before the adhesive is applied onto thecarrier'by directing a jet of warm or cool air toward the adhesive.

Preferably the surface of the first applicator 201 is sufficiently rigidand uncompressible so that it does not deform substantially duringapplication of the first patch. As shown in FIG. 2, the surface of thefirst appliv 202 by transfer from an offset applicator 203 whichapplicator 203 may be of the general size and construction detail as thefirst applicator 201.

FIG. 6 illustrates several of the sealant carriers 40 composed ofseparator material with their adhesive patches being assembled into acontinuous chain of multicell batteries. In the particular constructionshown in FIG. 6 the sealant carriers are spaced alternately withcontinuous strips of liquid impervious material 50 such as anelectrically conductive plastic. Intermittent deposits of positiveelectrodes 20 are spaced along one side of each strip 50, while on theother side of each strip 50 and substantially opposite the positiveelectrodes are intermittent deposits of negative electrodes 30. The area42 inside each adhesive patch is interposed between a positive electrode20 and a negative electrode 30 where it functions as a separator andelectrolyte retainer. Surrounding each deposit of positive electrode 20and negative electrode 30 is a patch of adhesive sealant 101 whichmatches with and seals to an adhesive patch 30] or 302 in the adjacentsealant carrier 40. It has been determined empirically that due to theimpervious nature of the material 50 only a minor quantity of adhesive,not enough to produce a quality seal, can be satisfactorily applied ontothe surface of the material 50, and therefore it is desirable tooverload the sealant carriers 40 with enough adhesive to produce thedesired seal; hence the desirability of having the surfaces of theadhesive patches 301 and 302 rise above the surfaces of the sealantcarrier 40, as shown in FIGS. 3 and 5.

FIG. 7 shows one of the assembled multicell batteries 5 after it hasbeen produced as shown in FIG. 6 and cut apart from other similarlyproduced batteries. FIG. 8 shows a cross section of the battery 5. FIG.8 illustrates how the adhesive patches which are impregnated into thesealant carriers 40 mate with and seal to the liquid impervious layers50 to produce liquid impervious seals around the perimeter of eachpositive electrode 20 and negative electrode 30.

FIG. 10 illustrates an alternative embodiment of the invention, one inwhich the sealant carrier 40A has a void area inside each adhesivepatch. A discrete piece of separator material 40B is placed into eachvoid area during assembly of the battery. All of the principles ofadhesive application discussed above are applicable to the embodimentshown in FIG. 10. It should be stated that whereas the use of separatormaterial for the sealant carrier as shown in FIGS. 1 through 6 and 8minimizes the number of structurally separate components and simplifiesthe steps required to assemble the batteries, it also requires the useof a material which is simultaneously a good sealant carrier, a goodseparator, and a good electrolyte retainer. On the other hand theconstruction shown in FIG. 10 increases the number of structurallyseparate components and complicates the steps required to assemble thebatteries, but permits S the sealant carrier 40A and the separators 4013to be selected from different materials each of which is best suited forits limited purpose.

The embodiments illustrated and described thus far I have utilized acontinuous strip of sealant carrier and a pair of rotary adhesiveapplicators which simultaneously apply a'succession of adhesive patchesto the opposite sides of the carrier web. Other embodiments of theinvention are also possible. For one, the rotary applicators may bestaggered so that they apply adhesive patches to the opposite sides ofthe carrier sequentially rather than simultaneously. To achieve thispractically, however, it is necessary to obtain proper registration ofthe second patches with the first. Because of the properties of mostsealant carriers which might be used with this invention (e.g.,nonuniformity along the length of the strip), the requirement to processthe carrier under tension, and the limitations of available machinery,it is sometimes difficult to attain the required precision inregistration when the first and second adhesive patches, are appliedsequentially, and hence there is a preference for simultaneousapplication.

The invention is not limited either to the use of com tinuous strips ofsealant carrier or to rotary adhesive applicators The principlesdescribed above the need to impregnate substantially throughout theentire thickness of the carrier, the need to have the surfaces of theadhesive patches rise above the surface of the carrier, the desirabilityof applying the adhesive for the second patches at a higher viscositythan that used for the first patches, the desirability of having onerigid and one elastomeric applicator all are applicable to otherembodiments in which the sealant carrier is processed as discretepieces'rather than as a continuous strip and/or in which applicators ofother constructions are employed. This invention is therefore not to beconstrued as being limited to use with continuous strips of sealantcarrier and/or rotary adhesive applicators.

FIG. 9 is shown to illustrate a general characteristic of heat sensitiveadhesives, namely that they become less viscous (i.e., more fluid) withincreases in temperature. Because this invention may be used with a widevariety of adhesives it is not possible to define within numericallimits the viscosities of the adhesives which optimize results. It isproper to say, however, that the proper viscosity in the adhesive may bedetermined by experimentation to obtain best results and that in genera] the relationship described and implied by FIG. 9 will be found toexist.

A wide variety of adhesives may be used with this invention. Theadhesives must be electrically nonconductive where used between twoelectrically conductive liquid impervious members between which thepassage of current is to be prevented. The adhesives themselves may beselected from a wide variety of materials including such adhesives aspolyamide and polyester hot melts, catalyzed uncured epoxy resins.phenolic resin solutions, ethylene copolymer hot melts, pressuresensitive elastomer mixtures, thermoplastic resin solution, and naturalgums and resins and their solutions, monomeric polymers (either alone orin mixture with other film forming materials), and combinations of thesematerials. Faster and more thorough and complete im pregnation of theadhesive into the carrier may be achieved with many hot melt cements bymaking the impregnations with heated adhesives. The adhesives which maybe used may be ones which attain their adhesive quality for the firsttime during assembly of the battery as a result of the application ofpressure, heat, Ultrasonics, electron beam bombardment, or other formsof energy.

The sealant carrier 40 may be made from a wide variety of materialsincluding the synthetic fibers,microporous polymer sheets, andcellulosic materials which are conventional in battery construction aswell as from woven or nonwoven fibrous materials such as polyester,nylon, polypropylene, polyethylene, rayon, acrylic, and combinations ofthese materials.

The batteries which may utilize the separators impregnated by thisinvention may employ a wide variety of positive and negative electrodematerials and a wide variety of electrochemical systems including bothprimary and secondary systems. Among the positive electrode materialsare such commonly used inorganic metal oxides as manganese dioxide, leaddioxide, nickel oxyhydroxide, mercuric oxide, and silver oxide, inorganic metal halides such as silver chloride and lead chloride, andorganic materials capable of being reduced such as dinitrobenzene andazodicarbonamide compounds. Among the negative electrode materials aresuch commonly used metals as zinc, aluminum, magnesium, lead, cadmium,and iron. This invention may employ the electrolytes commonly used inthe LeClanche system (ammonium chloride and/or zinc chloride), variousalkaline electrolytes such as the hydroxides of potassium, sodium,and/or lithium, acidic electrolytes such as sulfuric or phosphoric acid,and nonaqueous electrolytes, the electrolytes of course chosen to becompatible with the positive and negative electrodes.

Among the wide variety of electrochemical systems which may be used inthe batteries are those in which the positive electrodes comprisemanganese dioxide, the negative electrodes comprise metals such as zinc,aluminum, or magnesium, and the electrolyte substantially comprises anacidic solution of inorganic salts. Another commonly known system usefulin the batteries is the alkaline manganese system in which the positiveelectrodes comprise manganese dioxide, the negative electrodes comprisezinc, and the electrolyte substantially comprises a solution ofpotassium hydroxide. Other aqueous electrolyte systems including thoseof nickel-zinc, silver-zinc, mercury-zinc, mercurycadmium, andnickel-cadmium may also be used. Systems employing organic positiveelectrodes and acidic electrolytes may also be used includingrechargeable systems using azodicarbonamide compound electrodes andLeClanche electrolyte.

Where this invention is used in the construction of multicell batteries,any of several constructions of liquid impervious layers which functionsas intercell connectors may be used. The particular layers 50 shown inFIG. 8 comprise a single member made from an electrically conductiveplastic. The layers 50 might also comprise other electrically conductivesingle members such as metal sheets or foils, or they might collectivelycomprise two or more members each of which is conductive. Alternatively,layers 50 might each comprise the combination of a nonconductive memberand one or more conductive members which extend through or around theedge of the nonconductive member.

Examples will illustrate the practical application of the claimedconcepts.

EXAMPLE 1 The method and hardware illustrated by FIGS. 1 through 3 wereused to impregnate adhesive patches into a continuous strip of separatormaterial. The results are illustrated by FIGS. 4 and 5.

The first applicator roll 201 was made from steel plated first withcopper and then with hard chrome, was 9.738 inches in diameter, androtated at 31.2 rpm. lt had engraved areas of the length and widthdesired in the adhesive patches, with the depth of the engraved areasbeing 9 mils (thousandths of an inch) and the screen ruling in theengraved areas being 39 lines per inch. The second applicator roll 202was covered with Nordel white rubber, was 9.798 inches in diameter, androtated at 3 l .2 rpm. The offset applicator 203 had recessed areas ofthe width and length corresponding to those desired in the adhesivepatches, and the average depth of these areas was 12 mils; the screenruling in these engraved areas was 28 lines per inch; its diameter was9.738 inches and it rotated at'3 l .2 rpm. The spacing between thecenters of the applicators was 201, 202 and 203 was such that there wasan interference of approximately l/l6 inch between applicators 201 and202 and an interference of approximately /32 inch between applicators202 and 203, causing applicator 202 to be squeezed or compressed by eachof the other applicators. A separator strip made from Style No. 3006- DPellon polyester non-woven web material and having a normal,uncompressed thickness of 3.7 mils was passed between the applicators ata speed of approximately 40 linear feet per minute and under a tensionestimated to be approximately 2 pounds per linear inch. A General Millsexperimental polyamide resin No. TPX-6l7 adhesive at temperatures ofapproximately 350 and 300F was applied by the applicators 201 and 203respectively. The temperature of the adhesive on the surface ofapplicator 202 at the point immediately preceding the nip wasapproximately 235F. The surface of the resultant first adhesive patch301 illustrated in FIG. 5 rose above one side of the separator materialby an average of approximately 2 /2 mils, while the surface of theresultant second adhesive patch 302 rose above the surface of theopposite side of the separator by an average of approximately 2% mils.Microscopic inspections and oven tests showed that the first patch 301had been applied under sufficient tempera ture and pressure toimpregnate the separator material throughout the entire thickness of theseparator material and that enough adhesive was impregnated into theseparator to substantially prevent electrolyte from wicking from theareas 42 through the adhesive impregnations.

EXAMPLE 2 The process described in Example No. l was varied by usingFuller No. S-5026 hot melt adhesive, a commercially available blendknown to contain vinyl acetate resins, waxes, and antioxidants. Thetemperatures of the adhesive on the applicators 201, 202 and 203 wereapproximately 335, 210, and 275F, respectively. The reduced temperatureon applicator 202 was achieved by blowing cool air (70F) at the adhesiveon the surface of that applicator. The surface of the resultant firstadhesive patch 301 rose above one side of the separator material by anaverage of approximately 2% mils, while the surface of the resultantsecond adhesive patch 302 rose above the surface of the opposite side ofthe separator by an average of approximately 1% mils. No other machineconditions were changed. No other effects were observed.

Several additional observations should be made about aspects of theprocess.

First, it appears that there is a range of sealant carrier speeds withinwhich it is not necessary to heat or cool the elastomeric surface of thesecond applicator 202. Above this range of carrier speeds it isnecessary to heat the surface of the applicator 202, while below thisrange it should prove necessary to cool the surface. As mentionedearlier, the temperatures may be controlled by various temperaturecontrol devices or media internal to the applicators and/or by externaltemperature control devices such as hot air blowers, heating lamps, andothers.

The uniformity of the adhesive patches on the separator carrier may bepromoted by maximizing the screen ruling in the engraved areas onapplicators 201 and 203.

Finally, the choice of the adhesive should be viewed as being to someextent interdependent with the choice of sealant carrier material. Theadhesive must have an affinity for the fibres in the sealant carrier tomaximize the adhesive penetration into the carrier. In order to getsubstantially uniform thicknesses of adhesive above the surface of thesealant .carrier the carrier should have a substantially uniformporosity.

Having explained our invention, we claim:

1. An improvement in a method ofimpregnating adhesive patches into abattery sealant carrier comprising:

a. applying a first patch of adhesive onto one side of the sealantcarrier so that the first patch is in the form of a closed loop; and,

b. applying a second patch of adhesive onto the other side of thesealant carrier so that the second patch is in the form of a closed loopand so that the second patch is substantiallyopposite and coextensivewith the first patch, wherein the improvement comprises c. applying thefirst and second patches at different viscosities, and

d. applying at least one of the patches so that its surface rises abovethe surface of the sealant carrier.

2. The method of claim 1 in which the first and second patches areapplied simultaneously.

3. The method of claim 1 in which a. the first patch is applied by afirst applicator the surface of which has a recessed area in theconfiguration of the desired adhesive patch and in which the recessedarea contains adhesive to be transferred to the carrier strip, and

b. the second patch is applied by a second applicator on the surface ofwhich is a quantity of adhesive, which quantity of adhesive is of theconfiguration of the desired second patch and which quantity of adhesiverises above the surface of the second applicator.

4. The method of claim 1 in which a. the first patches are applied by anapplicator the surface of which is sufficiently rigid and uncompressibleso that it does not deform substantially during application of the firstpatches, and,

b. the second patches are applied by an applicator the surface of whichis sufficiently elastomeric so that it deforms during application of thesecond patches. Y

5. The method of claim 2 in which a. the first patch is applied by anapplicator the surface of which is sufficiently rigid and uncompressibleso that it does not deform substantially during application of the firstpatch, and

b. the second patch is applied by an applicator the surface of which issufficiently elastomeric so that it deforms during application of thesecond patch.

6. The method of claim 2 in which a. the first patch is applied by afirst applicator the surface of which has a recessed area in theconfiguration of the desired adhesive patch and in which the recessedarea contains adhesive to be transferred to the carrier strip, and

b. the second patch is applied by a second applicator on the surface ofwhich is a quantity of adhesive, which quantity of adhesive is of theconfiguration of the desired second patch and which quantity of adhesiverises above the surface of the second applicator 7. The method of claim3 in which a. the first patch is applied by an applicator the surface ofwhich is sufficiently rigid and uncompressible so that it does notdeform substantially during application of the first patch, and

b. the second patch is applied by an applicator the surface of which issufficiently elastomeric so that it deforms during application of thesecond patch.

8. The method of claim 6 in which a. the first patch is applied by afirst applicator the surface of which is sufficiently rigid anduncompressible so that it does not deform substantially duringapplication of the first patch, and

b. the second patch is applied by a second applicator the surface ofwhich is sufficiently elastomeric so that it deforms during applicationof the second patch.

9. An improvement in a method of impregnating adhesive patches into abattery sealant carrier comprisa. applying a first patch of adhesiveonto one side of the sealant carrier so that the first patch is in theform of a closed loop; and,

b. applying a second patch of adhesive onto the other side of thesealant carrier so that the first patch is in the form of a closed loopand so that the second patch is substantially opposite and coextensivewith the first patch, wherein the improvement comprises c. applying thefirst patch with a first applicator the surface of which has a recessedarea in the configuration of the desired adhesive patch and in which therecessed area contains adhesive to be transferred to the carrier strip,

(1. applying the second patch with a second applicator on the surface ofwhich is a quantity of adhesive, which quantity of adhesive is of theconfiguration of the desired second patch and which quantity of adhesiverises above the surface of the second applicator, and

e. applying at least one of the patches so that its surface rises abovethe surface of the sealant carrier.

10. The method of claim 9 in which a. the first patch is applied by afirst applicator the surface of which is sufficiently rigid anduncompressible so that it does not deform substantially duringapplication of the first patch, and

b. the second patch is applied by a second applicator the surface ofwhich is sufficiently elastomeric so that it deforms during applicationof the second patch.

11. An improvement in a method of impregnating adhesive patches into abattery sealant carrier comprising:

a. applying a first patch of adhesive onto one side of the sealantcarrier sothat the first patch is in the form of a closed loop; and

b. applying a second patchof adhesive onto the other side of the sealantcarrier so that the second patch is in the form of a closed loop and sothat the second patch is substantially opposite and coextensive with thefirst patch, wherein the improvement comprises c. applying the firstpatch with a first applicator the surface of which is sufficiently rigidand uncompressible so that it does not deform substantially duringapplication of the first patch,

d. applying the second patch with a second applicator the surface ofwhich is sufficiently elastomeric so that it deforms during applicationof the second patch, and

e. applying at least one of the patches so that its surface rises abovethe surface of the sealant carrier.

12. An improvement in a method ofimpregnating adhesive patches into acontinuous strip of a battery sealant carrier comprising:

a. applying a succession of first patches of adhesive onto one side ofacontinuous strip of batter sealant carrier so that each first patch isin the form of a closed loop; and,

b. applying a succession of second patches of adhesive onto the otherside of the sealant carrier so that each second patch is in the form ofa closed loop and so that each second patch is substantially oppositeand coextensive jwith a first patch, wherein the improvement comprisesc. applying the first and second patches at different viscosities, and

d. applying at least one of the patches so that its surface rises abovethe surface of the sealant carrier.

13. Thee method of claim 12 in which a. the first patches are applied byan applicator the surface of which is sufficiently rigid anduncompressible so that it does not deform substantially during theapplication of the first patches, and

b. the second patches are applied by an applicator the surface of whichis sufficiently elastomeric so that it deforms during application of thesecond patches.

14. The method of claim 12 il'll which the first and second patches areapplied simultaneously.

15. The method of claim 12 in which a. the first patch is applied by afirst, applicator the surface of which has a recessed area in theconfiguration of the desired adhesive patch and in which the recessedarea contains adhesive to be transferred to the carrier strip, and

b. the second patch is applied by a second applicator on the surface ofwhich is a quantity of adhesive, which quantity of adhesive is oftheconfiguration of the desired second patch and which quantity ofadhesive rises above the surface of the second applicator.

16. The method of claim 14 in which a. the first patch is applied by afirst applicator the surface of which has a recessed area in theconfiguration of the desired adhesive patch and in which the recessedare contains adhesive to be transferred to the carrier strip, and

b. the second patch is applied by a second applicator on the surface ofwhich is a quantity of adhesive, which quantity of adhesive is of theconfiguration of the desired second patch and which quantity of adhesiverises above the surface of the second applicator.

17. The method of claim 14 in which a. the first patches are applied byan applicator the surface of which is sufficiently rigid anduncompressible so that it does not deform substantially duringapplication of the first patches, and,

b. the second patches are applied by an applicator the surface of whichis sufficiently elastomeric so that it deforms during application of thesecond patches.

18. The method of claim 15 in which a. the first patches are applied byan applicator to the surface of which is sufficiently rigid anduncompressible so that it does not deform substantially duringapplication of the first patches, and,

b. the second patches are applied by an applicator the surface of whichis sufficiently elastomeric so that it deforms during application of thesecond patches.

19. The method of claim 16 in which a. the first patch is applied by anapplicator the surface of which is sufficiently rigid and uncompressibleso that it does not deform substantially during application of the firstpatch, and

b. the second patch is applied by a second applicator the surface ofwhich is sufficiently elastomeric so that it deforms during applicationof the second patch.

20. An improvement in a method of impregnating adhesive patches into acontinuous strip ofa battery sealant carrier comprising:

a. applying a succession of first patches of adhesive onto one side of acontinuous strip of battery sealant carrier so that each first patch isin the form of a closed loop; and,

b. applying a succession of second patches of adhesive onto the otherside of the sealant carrier so that each second patch is in the form ofa closed loop and so that each second patch is substantially oppositeand coextensive with a first patch, wherein the improvement comprises c.applying the first patches with a first applicator the surface of whichhas a recessed area in the configuration of the desired adhesive patchand in which the recessed area contains adhesive to be transferred tothe carrier strip,

d. applying the second patches with a second applicator on the surfaceof which is a quantity of adhesive, which quantity of adhesive is of theconfiguration of the desired second patch and which quantity of adhesiverises above the surface of the second applicator, and

e. applying at least one of the patches so that its surface rises abovethe surface of the sealant carrier.

21. The method of claim 20 in which a. the first patch is applied by anapplicator the surface of which is sufficiently rigid and uncompressibleso that it does not deform substantially during application of the firstpatch, and

b. the second patch is applied by an applicator the surface of whichsufficiently elastomeric so that it deforms during application of thesecond patch.

22. An improvement in a method of impregnating adhesive patches into acontinuous strip of battery sealant carrier comprising:

a. applying a succession of first patches of adhesive onto one side ofacontinuous strip of battery sealant carrier so that each first patch isin the form of a closed loop; and,

b. applying a succession of second patches of adhesive onto the otherside of the sealant carrier so that each second patch is in the form ofa closed loop and so that each second patch is substantially oppositeand coextensive with a first patch, wherein the improvement comprises 0.applying the first patches with a first applicator the surface of whichis sufficiently rigid and uncompressible so that it does not deformsubstantially during application of the first patches,

(1. applying the second patches with a second applicator the surface ofwhichis sufficiently elastomeric so that it deforms during applicationof the second patches, and,

e. applying at least one of the patches so that its surface rises abovethe surface of the sealant carrier.

2. The method of claim 1 in which the first and second patches areapplIed simultaneously.
 3. The method of claim 1 in which a. the firstpatch is applied by a first applicator the surface of which has arecessed area in the configuration of the desired adhesive patch and inwhich the recessed area contains adhesive to be transferred to thecarrier strip, and b. the second patch is applied by a second applicatoron the surface of which is a quantity of adhesive, which quantity ofadhesive is of the configuration of the desired second patch and whichquantity of adhesive rises above the surface of the second applicator.4. The method of claim 1 in which a. the first patches are applied by anapplicator the surface of which is sufficiently rigid and uncompressibleso that it does not deform substantially during application of the firstpatches, and, b. the second patches are applied by an applicator thesurface of which is sufficiently elastomeric so that it deforms duringapplication of the second patches.
 5. The method of claim 2 in which a.the first patch is applied by an applicator the surface of which issufficiently rigid and uncompressible so that it does not deformsubstantially during application of the first patch, and b. the secondpatch is applied by an applicator the surface of which is sufficientlyelastomeric so that it deforms during application of the second patch.6. The method of claim 2 in which a. the first patch is applied by afirst applicator the surface of which has a recessed area in theconfiguration of the desired adhesive patch and in which the recessedarea contains adhesive to be transferred to the carrier strip, and b.the second patch is applied by a second applicator on the surface ofwhich is a quantity of adhesive, which quantity of adhesive is of theconfiguration of the desired second patch and which quantity of adhesiverises above the surface of the second applicator.
 7. The method of claim3 in which a. the first patch is applied by an applicator the surface ofwhich is sufficiently rigid and uncompressible so that it does notdeform substantially during application of the first patch, and b. thesecond patch is applied by an applicator the surface of which issufficiently elastomeric so that it deforms during application of thesecond patch.
 8. The method of claim 6 in which a. the first patch isapplied by a first applicator the surface of which is sufficiently rigidand uncompressible so that it does not deform substantially duringapplication of the first patch, and b. the second patch is applied by asecond applicator the surface of which is sufficiently elastomeric sothat it deforms during application of the second patch.
 9. Animprovement in a method of impregnating adhesive patches into a batterysealant carrier comprising: a. applying a first patch of adhesive ontoone side of the sealant carrier so that the first patch is in the formof a closed loop; and, b. applying a second patch of adhesive onto theother side of the sealant carrier so that the first patch is in the formof a closed loop and so that the second patch is substantially oppositeand coextensive with the first patch, wherein the improvement comprisesc. applying the first patch with a first applicator the surface of whichhas a recessed area in the configuration of the desired adhesive patchand in which the recessed area contains adhesive to be transferred tothe carrier strip, d. applying the second patch with a second applicatoron the surface of which is a quantity of adhesive, which quantity ofadhesive is of the configuration of the desired second patch and whichquantity of adhesive rises above the surface of the second applicator,and e. applying at least one of the patches so that its surface risesabove the surface of the sealant carrier.
 10. The method of claim 9 inwhich a. the first patch is applied by a first applicator the surface ofwhich is sufficiently rigid and uncompressible so that it does notdeform suBstantially during application of the first patch, and b. thesecond patch is applied by a second applicator the surface of which issufficiently elastomeric so that it deforms during application of thesecond patch.
 11. An improvement in a method of impregnating adhesivepatches into a battery sealant carrier comprising: a. applying a firstpatch of adhesive onto one side of the sealant carrier so that the firstpatch is in the form of a closed loop; and b. applying a second patch ofadhesive onto the other side of the sealant carrier so that the secondpatch is in the form of a closed loop and so that the second patch issubstantially opposite and coextensive with the first patch, wherein theimprovement comprises c. applying the first patch with a firstapplicator the surface of which is sufficiently rigid and uncompressibleso that it does not deform substantially during application of the firstpatch, d. applying the second patch with a second applicator the surfaceof which is sufficiently elastomeric so that it deforms duringapplication of the second patch, and e. applying at least one of thepatches so that its surface rises above the surface of the sealantcarrier.
 12. An improvement in a method of impregnating adhesive patchesinto a continuous strip of a battery sealant carrier comprising: a.applying a succession of first patches of adhesive onto one side of acontinuous strip of batter sealant carrier so that each first patch isin the form of a closed loop; and, b. applying a succession of secondpatches of adhesive onto the other side of the sealant carrier so thateach second patch is in the form of a closed loop and so that eachsecond patch is substantially opposite and coextensive with a firstpatch, wherein the improvement comprises c. applying the first andsecond patches at different viscosities, and d. applying at least one ofthe patches so that its surface rises above the surface of the sealantcarrier.
 13. Thee method of claim 12 in which a. the first patches areapplied by an applicator the surface of which is sufficiently rigid anduncompressible so that it does not deform substantially during theapplication of the first patches, and b. the second patches are appliedby an applicator the surface of which is sufficiently elastomeric sothat it deforms during application of the second patches.
 14. The methodof claim 12 in which the first and second patches are appliedsimultaneously.
 15. The method of claim 12 in which a. the first patchis applied by a first applicator the surface of which has a recessedarea in the configuration of the desired adhesive patch and in which therecessed area contains adhesive to be transferred to the carrier strip,and b. the second patch is applied by a second applicator on the surfaceof which is a quantity of adhesive, which quantity of adhesive is of theconfiguration of the desired second patch and which quantity of adhesiverises above the surface of the second applicator.
 16. The method ofclaim 14 in which a. the first patch is applied by a first applicatorthe surface of which has a recessed area in the configuration of thedesired adhesive patch and in which the recessed are contains adhesiveto be transferred to the carrier strip, and b. the second patch isapplied by a second applicator on the surface of which is a quantity ofadhesive, which quantity of adhesive is of the configuration of thedesired second patch and which quantity of adhesive rises above thesurface of the second applicator.
 17. The method of claim 14 in which a.the first patches are applied by an applicator the surface of which issufficiently rigid and uncompressible so that it does not deformsubstantially during application of the first patches, and, b. thesecond patches are applied by an applicator the surface of which issufficiently elastomeric so that it deforms during application of thesecond patches.
 18. The Method of claim 15 in which a. the first patchesare applied by an applicator to the surface of which is sufficientlyrigid and uncompressible so that it does not deform substantially duringapplication of the first patches, and, b. the second patches are appliedby an applicator the surface of which is sufficiently elastomeric sothat it deforms during application of the second patches.
 19. The methodof claim 16 in which a. the first patch is applied by an applicator thesurface of which is sufficiently rigid and uncompressible so that itdoes not deform substantially during application of the first patch, andb. the second patch is applied by a second applicator the surface ofwhich is sufficiently elastomeric so that it deforms during applicationof the second patch.
 20. An improvement in a method of impregnatingadhesive patches into a continuous strip of a battery sealant carriercomprising: a. applying a succession of first patches of adhesive ontoone side of a continuous strip of battery sealant carrier so that eachfirst patch is in the form of a closed loop; and, b. applying asuccession of second patches of adhesive onto the other side of thesealant carrier so that each second patch is in the form of a closedloop and so that each second patch is substantially opposite andcoextensive with a first patch, wherein the improvement comprises c.applying the first patches with a first applicator the surface of whichhas a recessed area in the configuration of the desired adhesive patchand in which the recessed area contains adhesive to be transferred tothe carrier strip, d. applying the second patches with a secondapplicator on the surface of which is a quantity of adhesive, whichquantity of adhesive is of the configuration of the desired second patchand which quantity of adhesive rises above the surface of the secondapplicator, and e. applying at least one of the patches so that itssurface rises above the surface of the sealant carrier.
 21. The methodof claim 20 in which a. the first patch is applied by an applicator thesurface of which is sufficiently rigid and uncompressible so that itdoes not deform substantially during application of the first patch, andb. the second patch is applied by an applicator the surface of whichsufficiently elastomeric so that it deforms during application of thesecond patch.
 22. An improvement in a method of impregnating adhesivepatches into a continuous strip of battery sealant carrier comprising:a. applying a succession of first patches of adhesive onto one side of acontinuous strip of battery sealant carrier so that each first patch isin the form of a closed loop; and, b. applying a succession of secondpatches of adhesive onto the other side of the sealant carrier so thateach second patch is in the form of a closed loop and so that eachsecond patch is substantially opposite and coextensive with a firstpatch, wherein the improvement comprises c. applying the first patcheswith a first applicator the surface of which is sufficiently rigid anduncompressible so that it does not deform substantially duringapplication of the first patches, d. applying the second patches with asecond applicator the surface of which is sufficiently elastomeric sothat it deforms during application of the second patches, and, e.applying at least one of the patches so that its surface rises above thesurface of the sealant carrier.